RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 61/413,575, which was filed November 15, 2010.

BACKGROUND

[0002] This disclosure relates to composite bathing vessels.

[0003] Bathing vessels may be manufactured from a variety of different materials, such as plastic materials. Plastic bathing vessels, however, must meet certain minimum performance requirements. For instance, the American National Standards Institute (ANSI) sets forth minimum physical requirements and testing methods for plastic bathtub and shower units. A bathing vessel that meets the relevant requirements may be approved for use in homes, buildings or other structures as a plumbing fixture.

SUMMARY

[0004] An example bathing vessel includes a base support having a base board that extends between a top, a bottom, first and second side edges, and first and second ends. Two legs are attached on the bottom of the base board, inboard from the respective first and second side edges. The base board is at least partially encapsulated in a polyurethane material.

[0005] In another aspect, an example bathing vessel includes a base support having a base board that extends between a top, a bottom, first and second side edges, and first and second ends. The base board defines two spaced-apart arms at the first end. The base board is at least partially encapsulated in a polyurethane material.

[0006] An exemplary method of manufacturing a bathing vessel includes at least partially encapsulating the base support in a polyurethane material. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

[0008] Figure 1 shows an example bathing vessel.

[0009] Figure 2 shows a cross-section of a multi-layer structure of a wall of a bathing vessel.

[0010] Figure 3 shows a base support that is within a base of a bathing vessel.

[0011] Figure 4 shows a side view of the base of Figure 3.

[0012] Figure 5 shows a base board at least partially encapsulated within a polyurethane material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013] Figure 1 illustrates selected portions of an example bathing vessel 20. In general, the bathing vessel 20 includes a base 22 that serves as the bottom of the bathing vessel 20 and supports one or more walls 24. The walls 24 extend vertically from the base 22 to form a tub portion 26 and a shower surround potion 28. However, in alternative embodiments, the walls 24 may form only a tub portion 26 or only a shower surround portion 28 from the base 22. Thus, it is to be understood that the examples disclosed herein are not limited to the illustrated design.

[0014] Figure 2 shows a cross-section through a portion of one of the walls 24. The walls 24 have a multi-layer structure that generally includes a first layer of polyurethane material 30a, a second layer of polyurethane material 30b, a layer of acrylonitrile butadiene styrene (ABS) material 30c, and a layer of acrylic material 30d (collectively layers 30a-d), such as polymethylmethacrylate. As shown, the layer of acrylic material 30d is a top layer and is exposed for view to a user within the bathing vessel 20. The layers 30b and 30c are intermediate layers, and the layer 30a is a bottommost layer (cap layer) that is generally obscured from view of a user within the bathing vessel 20. Each of the layers 30a-d is bonded to its respective neighboring layer or layers. In embodiments, the specific materials and order of the layers 30a-d contribute to providing the bathing vessel with a desired degree of strength, such as to meet relevant standards of the American National Standards Institute (ANSI).

[0015] In embodiments, the layer of acrylic material 30d is arranged on the first layer of polyurethane material 30a, the layer of acrylonitrile butadiene styrene (ABS) material 30c is arranged between the layer of acrylic material 30d and the first layer of polyurethane material 30a, and the second layer of polyurethane material 30b is arranged between the layer of ABS material 30c and the first layer of polyurethane material 30a. In some examples, additional layers may be arranged among the layers 30a-d. In other examples, the walls 24 include only the layers 30a-d and are free of other layers, materials, adhesives, or the like.

[0016] The thicknesses of the individual layers 30a-d is not necessarily shown to scale and may vary, depending on the desired wall strength and location in the wall 24, for example. In embodiments, the ratio of the thickness of the layer of acrylic material 30d to the thickness of the layer of ABS material is no greater than 1, to facilitate meeting strength and deflection requirements, and the combined thickness of the layer of acrylic material 30d and the layer of ABS material 30c may be between 0.01 inches and 0.3 inches

[0017] In embodiments, the first layer of polyurethane material 30a, the second layer of polyurethane material 30b or both, are foamed polyurethane materials. In some examples, the density of the first layer of polyurethane material 30a is different than the density of the second layer of polyurethane material 30b. For instance, the density of the first layer of polyurethane material 30a is greater than the density of the second layer of polyurethane material 30b, to facilitate meeting strength and deflection requirements. A ratio between the density of the rigid polyurethane foam layer 30b and the thickness of the rigid polyurethane foam layer 30b is between 80-1: 1.

[0018] In a further example, the second layer of polyurethane material 30b is a rigid layer and has a density of 1-10 pounds per cubic foot. The first layer of polyurethane material 30a is an elastomeric layer and has a density of about 6.2-65 pounds per cubic foot, though in some examples the density is approximately 55-65 pounds per cubic foot. In one example, the density is approximately 62 pounds per cubic foot.

[0019] Referring to Figure 3 and Figure 4, the base 22 of the bathing vessel 20 includes a base board 40 that serves to reinforce the base 22 to meet strength and deflection requirements. In embodiments, the base board 40 is a wood-containing composite panel. The wood-containing composite panel may be a composite of wood particles held together with a polymeric resin material, such as but not limited to phenol formaldehyde or methyl diphenyl diisocyanate. The resin material of the wood-containing composite panel forms a strong chemical bond with the polyurethane material and thereby forms the strong composite structure of the base 22 of the bathing vessel 20. As an example, a chemical bond may refer to an attraction between atoms or molecules, such as covalent bonding, dipole-dipole interactions, London dispersion forces and hydrogen bonding. The strong bonding between the base board 40 and the polyurethane material also eliminates the need for any separate, distinct adhesive materials or layers to be used between the base board 40 and the polyurethane material.

[0020] The base board 40 extends between a top 42, a bottom 44, first and second side edges 46, 48, and first and second ends 50, 52. As shown, the base board 40 is generally flat, but alternatively may be contoured as desired. Supports, such as legs 54 and 56, are attached on the bottom 44 of the base board 40. The legs 54 and 56 may be attached using an adhesive, fasteners or the like. The legs 54 and 56 are attached inboard from the respective first and second side edges 46, 48. Although two legs 54, 56 are shown, it is to be understood that the supports may include multiple spaced-apart segments that together make up one of the legs 54 or 56.

[0021] The base board 40 defines two spaced-apart arms 58 and 60 at the first end 50. In the illustrated embodiment, each of the arms 58 and 60 are generally trapezoidal in shape and define an opening 62 there between, through which the drain of the bathing vessel 20 extends. As shown, the opening 62 is polygonal in shape. The shape of the arms 58 and 60, along with the shape of the opening 62, facilitate meeting strength and deflection requirements. That is, the arms 58 and 60 support the multilayer wall 24 to reduce deflection of the wall 24 in the area of the drain. Other numbers of arms are contemplated herein.

[0022] Referring to Figure 5, the base board 40 and legs 54 and 56 are designed to reduce deflection of the base 22 upon application of a load or loads to the base 22. The legs 54 and 56 are spaced apart from one another to define a span, S, there between. Each of the legs 54 and 56 is also arranged inboard a span, D, from respective first and second side edges 46, 48. As shown, the span D of each of the legs 54 and 56 may be nonequivalent. [0023] In embodiments, the span S between the legs 54 and 56 is no greater than 14 inches, and the span D between the legs 54 and 56 and the respective side edges 46 and 48 is no greater than 4 inches. In embodiments, a ratio S/D is 3.5, to facilitate meeting strength and deflection requirements. The base board 40 also defines a thickness, T, between the top 42 and the bottom 44. In embodiments a ratio S/T is 17.5-56, to facilitate meeting strength and deflection requirements.

[0024] Additionally, the arms 58 and 60 define a span, Si, there between. In some examples, the span Si is less than the span S between the legs 54 and 56. The given ratios and the multi-layer structure of the walls 24 contribute to meeting desired strength and deflection requirements.

[0025] The base board 40 is at least partially encapsulated within the first layer of polyurethane material 30a. The other layers 30b-d are disposed on the first layer of polyurethane material 30a as generally shown in Figure 2. The polyurethane material may be applied to the base board 40 by spraying an uncured polyurethane material, such as a two-part polyurethane mixture. The polyurethane material may extend entirely across the top 42 of the base board 40, around the side edges 46 and 48, and partially onto the bottom 44. In embodiments, the polyurethane material covers at least 50% of the surface area of the base board 40, with regard to the total surface area of the top 42, side edges 46 and 48, and bottom 44. In a further example, the polyurethane material does not completely encapsulate the base board such that less than 100% of the surface area of the base board 40 is covered. The mechanical encapsulation also further eliminates the need for any separate, distinct adhesive materials or layers to be used between the base board 40 and the polyurethane material. The base board 40 is thereby affixed within the multi-layer structure of the wall 24.

[0026] In the illustrated example, a portion of the bottom 44 of the base board 40 and the legs 54, 56 are not covered by the polyurethane material. Alternatively, the polyurethane material may be applied only to the top 42 of the base board, or only to the top and sides 46 and 48 of the base board 40. In another alternative, the entire base board 40, including the top 42, bottom 44, sides 46 and 48, and legs 54 and 56 may be encapsulated on all sides in the polyurethane material.

[0027] The spacing of the legs 54 and 56 inboard from the first and second side edges 46 and 48 of the base board 40 also strengthens the base 22. For instance, the polyurethane material does not bridge between the flat portion of the base board 40 and the legs 54 and 56. As a comparison, if the legs 54 and 56 were at the first and second side edges 46 and 48, the polyurethane material may bridge at the corners of the flat portion of the base board 40 and the legs 54 and 56. The bridging forms a weaker area that may crack under stress and weaken the structure.

[0028] Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.

[0029] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.